U.S. patent number 10,502,001 [Application Number 14/933,908] was granted by the patent office on 2019-12-10 for earth-boring tools carrying formation-engaging structures.
This patent grant is currently assigned to Baker Hughes, a GE company, LLC. The grantee listed for this patent is Baker Hughes, a GE company, LLC. Invention is credited to Juan Miguel Bilen, Kenneth R. Evans, Don Quy Nguyen, Steven C. Russell.
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United States Patent |
10,502,001 |
Nguyen , et al. |
December 10, 2019 |
Earth-boring tools carrying formation-engaging structures
Abstract
An earth-boring tool includes a blade located on a body of the
earth-boring tool with a pocket formed in an exposed outer surface
of the blade. A formation-engaging structure is affixed within the
pocket. The formation-engaging structure includes a distal end, a
proximal end and a tapered sidewall therebetween. The distal end of
the formation-engaging structure includes a formation-engaging
surface. The tapered sidewall engages a tapered inner surface of
the pocket. The tapered sidewall of the formation-engaging
structure and the tapered inner surface of the pocket are each
sized and configured to provide an interference fit between the
formation-engaging structure and the pocket of the blade. In
additional embodiments, instead of retention by interference fit,
the formation-engaging structure is retained to the blade by a
threaded fastener threaded within a tapped bore extending through
the blade. The threaded fastener is received within a receiving
formation of the formation-engaging structure.
Inventors: |
Nguyen; Don Quy (Houston,
TX), Bilen; Juan Miguel (The Woodlands, TX), Russell;
Steven C. (Houston, TX), Evans; Kenneth R. (Spring,
TX) |
Applicant: |
Name |
City |
State |
Country |
Type |
Baker Hughes, a GE company, LLC |
Houston |
TX |
US |
|
|
Assignee: |
Baker Hughes, a GE company, LLC
(Houston, TX)
|
Family
ID: |
58667925 |
Appl.
No.: |
14/933,908 |
Filed: |
November 5, 2015 |
Prior Publication Data
|
|
|
|
Document
Identifier |
Publication Date |
|
US 20170130534 A1 |
May 11, 2017 |
|
Current U.S.
Class: |
1/1 |
Current CPC
Class: |
E21B
10/633 (20130101); E21B 10/55 (20130101) |
Current International
Class: |
E21B
10/633 (20060101); E21B 10/55 (20060101) |
References Cited
[Referenced By]
U.S. Patent Documents
Foreign Patent Documents
Other References
Bilen et al., U.S. Appl. No. 14/272,369 entitled Formation-Engaging
Assemblies, Earth-Boring Tools Including Such Assemblies and
Related Methods, filed May 7, 2014. cited by applicant .
Do et al. U.S. Appl. No. 14/272,360 entitled Formation-Engaging
Structures Having Retention Features, Earth-Boring Tools Including
Such Structures and Related Methods, filed May 7, 2014. cited by
applicant .
Miller et al., U.S. Appl. No. 14/276,587 entitled Earth-Boring
Tools Including Bearing Element Assemblies, and Related Methods,
filed May 13, 2014. cited by applicant.
|
Primary Examiner: Fuller; Robert E
Assistant Examiner: Quaim; Lamia
Attorney, Agent or Firm: TraskBritt
Claims
What is claimed is:
1. An earth-boring tool, comprising: at least one blade located on
a body of the earth-boring tool; cutting elements positioned in
respective cutting element pockets on an exposed outer surface of
the at least one blade, wherein the cutting elements comprise a
polycrystalline diamond compact; a pocket opening onto the exposed
outer surface of the at least one blade; a tapped bore extending
through the at least one blade from at least one of a rotationally
leading surface and a rotationally trailing surface of the at least
one blade to the pocket, the rotationally leading surface being a
leading surface of the blade as the at least one blade rotates
around an axis of rotation of the body of the earth-boring tool,
the rotationally trailing surface being a trailing surface of the
blade as the at least one blade rotates around the axis of rotation
of the body of the earth-boring tool; a formation-engaging
structure received within the pocket of the at least one blade, the
formation-engaging structure positioned intermediate at least two
cutting elements along a radial axis of the body of the
earth-boring tool, the formation-engaging structure having a distal
end, a proximal end and a sidewall therebetween, and the distal end
of the formation-engaging structure having a formation-engaging
surface; a receiving formation located in the sidewall of the
formation-engaging structure; and a threaded fastening element
threaded within the tapped bore extending through the at least one
blade, the threaded fastening element threadably engaging threads
of the tapped bore, a first end of the threaded fastening element
engaging the receiving formation of the formation-engaging
structure, the threaded fastening element, as engaged, configured
to retain the formation-engaging structure within the pocket of the
at least one blade.
2. The earth-boring tool of claim 1, wherein the receiving
formation comprises a receiving surface configured to engage the
first end of the threaded fastening element.
3. The earth-boring tool of claim 2, wherein the receiving surface
is oriented at a non-parallel angle in relation to a longitudinal
axis of the formation-engaging structure.
4. The earth-boring tool of claim 3, wherein the tapped bore is
oriented at a non-perpendicular angle in relation to the
longitudinal axis of the formation-engaging structure.
5. The earth-boring tool of claim 3, wherein the receiving surface
of the receiving formation is planar, and the threaded fastening
element comprises a set screw with a swivel tip having a planar
bearing surface oriented co-planar with the receiving surface.
6. The earth-boring tool of claim 1, further comprising a second
threaded fastening element threaded within the tapped bore, a
second end of the threaded fastening element adjacent a first end
of the second threaded fastening element, the second threaded
fastening element retaining the threaded fastening element within
the tapped bore.
7. The earth-boring tool of claim 1, wherein the formation-engaging
surface of the formation-engaging structure is ovoid.
8. The earth-boring tool of claim 1, wherein the formation-engaging
structure comprises a volume of superabrasive material disposed
over a substrate, the formation-engaging surface comprising a
surface of the volume of superabrasive material.
9. The earth-boring tool of claim 8, wherein the volume of
superabrasive material of the formation-engaging structure
comprises polycrystalline diamond.
10. The earth-boring tool of claim 2, wherein an outer surface of
the receiving surface of the receiving formation is recessed
relative to an outer surface of the sidewall of the
formation-engaging structure.
11. The earth-boring tool of claim 1, wherein the cutting elements
are located on the rotationally leading surface of the at least one
blade and the formation-engaging structure is located rotationally
behind the cutting elements.
12. The earth-boring tool of claim 1, wherein the
formation-engaging structure is located at a rotationally leading
position relative to the cutting elements.
13. The earth-boring tool of claim 1, wherein the
formation-engaging structure is an insert.
14. The earth-boring tool of claim 1, wherein the
formation-engaging structure is a non-cutting bearing element
positioned and oriented on the body as a rubbing surface configured
to rub against a formation as the body of the earth-boring tool is
rotated within a wellbore.
15. The earth-boring tool of claim 1, wherein the earth-boring tool
comprises a fixed-cutter earth-boring rotary drill bit comprising a
bit body having generally radially projecting and longitudinally
extending blades, the pocket being located on a leading end of a
respective blade.
16. The earth-boring tool of claim 1, wherein the tapped bore
comprises a blind bore extending through the at least one blade
from the rotationally trailing surface of the at least one blade to
the pocket.
17. The earth-boring tool of claim 1, wherein each of the threaded
fastening element and the receiving formation of the
formation-engaging structure are sized and configured to rigidly
retain the formation-engaging structure within the pocket of the at
least one blade.
18. The earth-boring tool of claim 1, wherein the
formation-engaging surface of the formation-engaging structure
comprises a wear-resistant material comprising cemented tungsten
carbide.
Description
CROSS-REFERENCE TO RELATED APPLICATIONS
The subject matter of this application is related to the subject
matter of U.S. patent application Ser. No. 14/272,360, filed on May
7, 2014 now U.S. Pat. No. 9,359,826, issued Jun. 7, 2016, in the
name of Van Do et al., to the subject matter of U.S. patent
application Ser. No. 14/272,369, filed on May 7, 2014 now U.S. Pat.
No. 9,476,257, issued Oct. 25, 2016, in the name of Bilen et al.,
and to the subject matter of U.S. application Ser. No. 14/276,587,
filed on May 13, 2014, in the name of Miller et al., the entire
disclosure of each of which is incorporated herein by this
reference.
TECHNICAL FIELD
Embodiments of the present disclosure relate to earth-boring tools
carrying formation-engaging structures and, more particularly, to
retention features retaining the formation-engaging structures on
the earth-boring tools.
BACKGROUND
Earth-boring tools are used to form boreholes (e.g., wellbores) in
subterranean formations. Such earth-boring tools include, for
example, drill bits, reamers, mills, etc. For example, a
fixed-cutter earth-boring rotary drill bit (often referred to as a
"drag" bit) generally includes a plurality of cutting elements
secured to a face of a bit body of the drill bit. The cutters are
fixed in place when used to cut formation materials. A conventional
fixed-cutter earth-boring rotary drill bit includes a bit body
having generally radially projecting and longitudinally extending
blades. During drilling operations, the drill bit is positioned at
the bottom of a well borehole and rotated.
A plurality of cutting elements is positioned on each of the
blades. The cutting elements commonly comprise a "table" of
superabrasive material, such as mutually bound particles of
polycrystalline diamond, formed on a supporting substrate of a hard
material, such as cemented tungsten carbide. Such cutting elements
are often referred to as "polycrystalline diamond compact" (PDC)
cutting elements or cutters. The plurality of PDC cutting elements
may be fixed within cutting element pockets formed in rotationally
leading surfaces of each of the blades. Conventionally, a bonding
material, such as a braze alloy, may be used to secure the cutting
elements to the bit body.
Some earth-boring tools may also include bearing elements that may
limit the depth-of-cut (DOC) of the cutting elements, protect the
cutting elements from excessive contact with the formation, enhance
(e.g., improve) dynamic stability of the tool, or perform other
functions or combinations of functions. The bearing elements
conventionally are located entirely rotationally behind associated
leading cutting elements to limit DOC as the bearing elements
contact and ride on an underlying earth formation, although bearing
elements rotationally leading cutting elements are also known.
BRIEF SUMMARY
In one embodiment of the disclosure, an earth-boring tool comprises
a blade located on a body of the earth-boring tool with a pocket
formed in an exposed outer surface of the blade. The earth-boring
tool includes a formation-engaging assembly affixed within the
pocket. The formation-engaging assembly comprises a
formation-engaging structure disposed within a holder. The holder
has a distal end, a proximal end and a tapered sidewall
therebetween. The tapered sidewall engages a tapered inner surface
of the pocket. The tapered sidewall of the holder and the tapered
inner surface of the pocket are each sized and configured to
provide an interference fit between the holder and the pocket of
the blade. A formation-engaging surface of the formation-engaging
structure extends from the distal end of the holder.
In another embodiment of the disclosure, an earth-boring tool
comprises a blade located on a body of the earth-boring tool with a
pocket formed in an exposed outer surface of the blade. A
formation-engaging structure is affixed within the pocket. The
formation-engaging structure has a distal end, a proximal end and a
tapered sidewall therebetween. The distal end of the
formation-engaging structure includes a formation-engaging surface.
The tapered sidewall engages a tapered inner surface of the pocket.
The tapered sidewall of the formation-engaging structure and the
tapered inner surface of the pocket are each sized and configured
to provide an interference fit between the formation-engaging
structure and the pocket of the blade.
In yet another embodiment of the disclosure, an earth-boring tool
comprises a blade located on a body of the earth-boring tool with a
pocket formed in an exposed outer surface of the blade. A tapped
bore extends from at least one of a rotationally leading surface
and a rotationally trailing surface of the blade to the pocket. The
earth-boring tool includes a formation-engaging structure affixed
within the pocket. The formation-engaging structure has a distal
end, a proximal end and a sidewall therebetween. The distal end of
the formation-engaging structure includes a formation-engaging
surface. A receiving formation is formed in the sidewall of the
formation-engaging structure. A threaded fastening element is
threaded within the tapped bore such that a first end of the
threaded fastening element engages the receiving formation of the
formation-engaging structure. The threaded fastening element
retains the formation-engaging structure within the pocket.
BRIEF DESCRIPTION OF THE SEVERAL VIEWS OF THE DRAWINGS
While the specification concludes with claims particularly pointing
out and distinctly claiming what are regarded as embodiments of the
present invention, various features and advantages of disclosed
embodiments may be more readily ascertained from the following
description when read with reference to the accompanying drawings,
in which:
FIG. 1 is a perspective view of an earth-boring drill bit with
formation-engaging structures, according to an embodiment of the
present disclosure;
FIG. 2 is a side, cross-sectional view of a formation-engaging
structure carried by a holder that is attached by interference fit
to a blade of an earth-boring tool, according to an embodiment of
the present disclosure;
FIG. 3 is a side, cross-sectional view of a formation-engaging
structure directly attached by interference fit to a blade of an
earth-boring tool, according to an embodiment of the present
disclosure;
FIG. 4 is a side, cross-sectional view of a formation-engaging
structure attached by a threaded fastener to a blade of an
earth-boring tool, according to an embodiment of the present
disclosure;
FIG. 5 is a side, cross-sectional view of a formation-engaging
structure attached by a first threaded fastener to a blade of an
earth-boring tool, with a second threaded fastener retaining the
first threaded fastener in place, according to an embodiment of the
present disclosure;
FIG. 6 is a side, partial cross-sectional view of a
formation-engaging structure configured to be attached by a
threaded fastener to a blade of an earth-boring tool, the threaded
fastener having a swivel tip configured to engage a corresponding
receiving formation formed in a sidewall of the formation-engaging
structure, according to an embodiment of the present
disclosure;
FIG. 7 is a side, partial cross-sectional view of a
formation-engaging structure similar to that shown in FIG. 6,
wherein the receiving formation in the sidewall of the
formation-engaging structure includes an inclined surface, and the
swivel tip of the threaded fastener is configured to engage the
inclined receiving surface, according to an embodiment of the
present disclosure;
FIG. 8 is a side, cross-sectional view of a formation-engaging
structure attached by a threaded fastener to a blade of an
earth-boring tool, the threaded fastener oriented at an angle with
respect to a longitudinal axis of the formation-engaging structure,
according to an embodiment of the present disclosure.
FIG. 9 is a perspective view of the formation-engaging structure
shown in FIGS. 4 and 5;
FIG. 10 is a perspective view of the formation-engaging structure
shown in FIG. 6; and
FIG. 11 is a perspective view of the formation-engaging structure
shown in FIG. 7.
DETAILED DESCRIPTION
The illustrations presented herein are not actual views of any
particular material, cutting element, formation-engaging structure,
or earth-boring tool, but are merely idealized representations
employed to describe embodiments of the present disclosure.
Additionally, elements common between figures may retain the same
numerical designation.
As used herein, the term "earth-boring tool" means and includes any
tool used to remove formation material and form a bore (e.g., a
wellbore) through the formation by way of removing the formation
material. Earth-boring tools include, for example, rotary drill
bits (e.g., fixed-cutter or "drag" bits and roller cone or "rock"
bits), hybrid bits including both fixed cutters and roller
elements, coring bits, percussion bits, bi-center bits, reamers
(including expandable reamers and fixed-wing reamers), and other
so-called "hole-opening" tools, etc.
FIG. 1 is a perspective view of an embodiment of an earth-boring
tool 100 of the present disclosure. The earth-boring tool 100 of
FIG. 1 is configured as an earth-boring rotary drill bit, although
other types of earth-boring tools are within the scope of the
present disclosure. The earth-boring tool 100 may comprise a
plurality of cutting elements 102 affixed to a body 104 of the
earth-boring tool 100. The earth-boring tool 100 may include one or
more formation-engaging structures 106 affixed to
formation-engaging structure holders 107 that are attached to the
body 104. The formation-engaging structures 106 may comprise, for
example, cutting elements, bearing elements, or wear knots. The
formation-engaging structures 106 and/or the holders 107 may
include features that interact with features of the earth-boring
tool 100 to facilitate retention of the formation-engaging
structures 106 within the earth-boring tool 100 and removal of the
formation-engaging structures 106 from the earth-boring tool 100,
as discussed in further detail below.
The body 104 of the earth-boring tool 100 may be secured to a shank
108 having a threaded connection portion 110, which may conform to
industry standards, such as those promulgated by the American
Petroleum Institute (API), for attaching the earth-boring tool 100
to a drill string (not shown).
The body 104 may include internal fluid passageways that extend
between fluid ports 112 at the face of the body 104 and a
longitudinal bore that extends through the shank 108 and partially
through the body 104. Nozzle inserts 114 may be secured within the
fluid ports 112 of the internal fluid passageways. The body 104 may
further include a plurality of blades 116 that are separated by
fluid courses 118, which may be referred to in the art as "junk
slots." In some embodiments, the body 104 may include gage wear
plugs 120, wear knots 122, or both.
Each formation-engaging structure 106 may be positioned on a blade
116 to rotationally trail at least one cutting element 102, as
shown in FIG. 1. In some embodiments, the formation-engaging
structures 106 may be positioned to rotationally lead cutting
elements 102 located on a rotationally trailing blade or optionally
on the same blade 116, or the formation-engaging structures 106 may
be disposed at positions intermediate at least two cutting elements
102 along a radial axis. The formation-engaging structures 106 may
be formed partially or fully of a wear-resistant material, such as
cemented tungsten carbide, or distal ends thereof may comprise a
wear-resistant material, such as cemented tungsten carbide, or a
superabrasive material, such as polycrystalline diamond or cubic
boron nitride. The wear-resistant material may comprise a coating
or particles of the wear-resistant material over an entirety of the
distal end, or inserts of the wear-resistant material embedded in a
surface of the distal end. In some embodiments, the
formation-engaging structures 106 may comprise a volume of
superabrasive material, such as polycrystalline diamond, at the
distal ends thereof disposed over substrates of wear-resistant
material, such as cemented tungsten carbide.
FIG. 2 illustrates a side, cross-sectional view of a blade 116
carrying the formation-engaging structure 106 and the
formation-engaging structure holder 107 shown in FIG. 1. The
formation-engaging structure 106 and the holder 107 may
collectively be termed a "formation-engaging assembly" 200. The
formation-engaging structure 106 may include a formation-engaging
surface 204 at a distal end 206 opposite a proximal end 208 with a
side surface 210 of the formation-engaging structure 106 extending
between the distal end 206 and the proximal end 208. The side
surface 210 of the formation-engaging structure 106 may also be
characterized as a sidewall. The formation-engaging surface 204 may
comprise a convex shape, such as a shape generally defined by a
portion of a sphere. In some embodiments, the formation-engaging
surface 204 may be substantially hemispherical or have an ovoid
shape. Such a formation-engaging structure 106 may be referred to
in the art as an "insert." In some embodiments, the
formation-engaging surface 204 may be generally conical or
chisel-shaped. In some embodiments, the formation-engaging surface
204 may comprise an asymmetrical shape. In the embodiment of FIG.
2, the side surface 210 of the formation-engaging structure 106 may
comprise a circular transverse cross-sectional shape, imparting to
the side surface 210 a substantially cylindrical shape. In other
embodiments, the cross-sectional shape may include, without
limitation, other shapes, such as ellipses, polygons, and shapes
including both arcuate and rectilinear portions.
The formation-engaging structure holder 107 may comprise a metal
alloy, such as a steel alloy, or may comprise a cemented tungsten
carbide matrix material, by way of non-limiting example. The holder
107 may include a receptacle 212 for accepting at least a portion
of the side surface 210 of the formation-engaging structure 106.
The sidewall of the receptacle 212 may comprise a cross-sectional
shape and size similar to the cross-sectional shape and size of the
side surface 210 of the formation-engaging structure 106, such that
the formation-engaging structure 106 fits tightly within the
receptacle 212. In some embodiments, the sizes of the
cross-sectional shapes of the receptacle 212 and the side surface
210 may be chosen to provide a clearance between the side surface
210 and a sidewall of the receptacle 212 to facilitate affixing the
formation-engaging structure 106 within the holder 107, with, for
example, a braze or adhesive.
As a non-limiting example, the formation-engaging structure 106 may
be brazed within the receptacle 212 or attached within the
receptacle mechanically or with an adhesive, as more fully
described in U.S. patent application Ser. No. 14/272,369, filed May
7, 2014, which has been incorporated herein by reference. The
receptacle 212 may extend from a distal end 218 of the holder 107 a
predetermined depth into the holder 107, as also more fully
described in U.S. patent application Ser. No. 14/272,369.
The formation-engaging assembly 200 may be affixed to the blade 116
within a pocket 220 formed in an exposed outer surface 222 of the
blade 116. The holder 107 may have a side surface 223 extending
between the distal end 218 and a proximal end 224 of the holder
107. The side surface 223 of the holder 107 may also be
characterized as a sidewall. The side surface 223 of the holder 107
may comprise a cross-sectional shape and size similar to the
cross-sectional shape and size of an inner surface of the pocket
220, such that the holder 107 fits tightly within the receptacle
pocket 220. A portion 226 of the side surface 223 of the holder 107
may be tapered and may be sized and configured to mate with a
tapered inner surface 228 of the pocket 220 in a manner providing
an interference fit between the holder 107 and the pocket 220. The
holder 107 may be inserted into the pocket 220 and subsequently
driven into the pocket 220 by a hammer and punch, a press, such as
a hydraulic press, or another suitable tool, until the holder 107
is fully disposed within the pocket 220 and retained by an
interference fit between the tapered portion 226 of the side
surface 223 of the holder 107 and the tapered inner surface 228 of
the pocket 220. In other embodiments, the holder 107 may be shrink
fitted within the pocket 220 (alternatively, or, in addition to the
foregoing insertion methods). Accordingly, the radius of the
tapered portion 226 of the holder 107 may be slightly larger than
the radius of the tapered inner surface 228 of the pocket 220 at
corresponding longitudinal positions of the tapered portion 226 of
the holder 107 and the tapered inner surface 228 of the pocket 220.
It is to be appreciated that the holder 107 may be affixed within
the pocket 220 prior to or after the formation-engaging structure
106 is attached within the receptacle 212 of the holder 107.
As shown in FIG. 2, the holder 107 may be pressed into the pocket
220 until the distal end 218 of the holder 107 is flush with the
exposed outer surface 222 of the blade 116. However, in other
embodiments (not shown), the distal end 218 of the holder 107 may
be upstanding or recessed from the exposed outer surface 222 of the
blade 116 when the holder 107 is affixed within the pocket 220
With continued reference to FIG. 2, the blade 116, the pocket 220
and the holder 107 may include features configured to facilitate
removal of the formation-engaging assembly 200 from the blade 116.
For example, a bore 234 may extend through the blade 116 in a
manner such that the proximal end 224 of the holder 107 extends
within the bore 234. The bore 234 may be sized and oriented such
that an operator may use a tool, such as a tapered punch 235, to
drive the formation-engaging assembly 200 out of the pocket 220. It
is to be appreciated that other tools for removing the
formation-engaging assembly 200 from the pocket 220 are within the
scope of the present embodiments, including a drift pin or even
fluid pressure exerted within the bore 234 by one or more fluid
pressure transferring mediums. As shown, the bore 234 may extend
entirely through the blade 116 (i.e., from the rotationally leading
surface 236 to the rotationally trailing surface 238 of the blade
116). In other embodiments (not shown), the bore 234 may be a blind
bore that extends from either the rotationally leading surface 236
of the blade 116 or the rotationally trailing surface 238 of the
blade 116 and underlies the proximal end 224 of the holder 107. It
is to be appreciated that the size and orientation of the bore 234
may be varied based on a number of factors that may affect removal
of the formation-engaging assembly 200 from the pocket 220, such
as, by way of non-limiting example, the design of the blade 116
and/or the design of the formation-engaging assembly 200.
Referring now to FIG. 3, a formation-engaging structure 306 may be
attached within a pocket 320 of a blade 316 by interference fit
directly between the formation-engaging structure 306 and the
pocket 320. In such embodiments, the formation-engaging structure
306 may have a side surface 323 extending between a distal end 318
and a proximal end 324 of the formation-engaging structure 306. The
side surface 323 of the formation-engaging structure 306 may also
be characterized as a sidewall. The side surface 323 of the
formation-engaging structure 306 may comprise a cross-sectional
shape and size similar to the cross-sectional shape and size of an
inner surface of the pocket 320, such that the formation-engaging
structure 306 fits tightly within the pocket 320. A portion 326 of
the side surface 323 of the formation-engaging structure 306 may be
tapered and may be sized and configured to mate with a tapered
inner surface 328 of the pocket 320 in a manner providing an
interference fit between the formation-engaging structure 306 and
the pocket 320. The formation-engaging structure 306 may be
inserted into the pocket 320 and subsequently driven into the
pocket 320 by a hammer and punch, a press, such as a hydraulic
press, or another suitable tool, until the formation-engaging
structure 306 is fully disposed within the pocket 320 and retained
by an interference fit between the tapered portion 326 of the side
surface 323 of the formation-engaging structure 306 and the tapered
inner surface 328 of the pocket 320, similarly as previously
described with respect to the embodiment of FIG. 2.
As with the embodiment shown in FIG. 2, the blade 316, the pocket
320 and the formation-engaging structure 306 of FIG. 3 may include
features configured to facilitate removal of the formation-engaging
structure 306 from the blade 316. For example, a bore 334 may
extend through the blade 316 and may underlie the
formation-engaging structure 306 such that the proximal end 324 of
the formation-engaging structure 306 extends within the bore 334.
The bore 334 is shown in FIG. 3 as a blind bore extending from the
rotationally leading surface 336 of the blade 316; however, it is
to be understood that the bore 334 may be a blind bore extending
from the rotationally trailing surface 338 of the blade 316 or may
be a through bore. The bore 334 may be sized and oriented such that
an operator may use a tool, such as a tapered punch (FIG. 2), to
drive the formation-engaging structure 306 out of the pocket 320,
as previously described. It is to be appreciated that other
embodiments for removing the formation-engaging structure 306 from
the pocket 320 are within the scope of the present disclosure,
including a drift pin or even utilizing fluid pressure exerted
within the bore 234 by one or more fluid pressure transferring
mediums.
FIG. 4 illustrates an embodiment of a formation-engaging structure
406 attached to a blade 416 of an earth-boring tool by a threaded
fastening element, such as a set screw 440. The formation-engaging
structure 406 may be received within a pocket 420 of the blade 416,
as previously described. A receiving formation 442 may optionally
be formed in a sidewall 423 of the formation-engaging structure 406
and may be substantially aligned with a tapped bore 444 extending
through the blade 416 from a rotationally trailing surface 438 of
the blade 416 to the pocket 420; however, in other embodiments, the
tapped bore 444 may extend from a rotationally leading surface 436
of the blade 416. The receiving formation 442 may include a blind
bore terminating at a recessed receiving surface 446, which may
optionally be planar. The set screw 440 may be threaded within the
tapped bore 444 until a leading end 448 of the set screw 440
engages the receiving surface 446 of the receiving formation 442 of
the formation-engaging structure 406. The leading end 448 of the
set screw 440 and the receiving formation 442 of the
formation-engaging structure 406 may be correspondingly sized and
configured to rigidly retain the formation-engaging structure 406
within the pocket 420. In other embodiments, the formation-engaging
structure 406 need not have a recessed receiving formation; in such
embodiments, the leading end 448 of the set screw 440 may abut the
sidewall 423 of the formation-engaging structure 406 with
sufficient force to retain the formation-engaging structure 406
within the pocket 420.
It is to be appreciated that, during an earth-boring operation, the
drill string (not shown), and an earth-boring tool coupled thereto,
may experience significant amounts of vibration and other
disruptive phenomena, which may, in some instances, over time,
cause the set screw 440 to counter-rotate within the tapped bore
444 (i.e., unscrew) from the position rigidly retaining the
formation-engaging structure 406 within the pocket 420. As shown in
FIG. 5, to prevent such unwanted unscrewing of the set screw 440, a
second set screw 450 may be threaded within the tapped bore 444
until a leading end of the second set screw abuts a trailing end of
the first set screw 440 in a manner retaining the first set screw
440 in the position rigidly retaining the formation-engaging
structure 406 with the pocket 420. The presence of the second set
screw 450 may effectively prolong the retention capabilities of the
first set screw 440, particularly in earth-boring operations
resulting in high amounts of vibration on the earth-boring tool
and/or on the formation-engaging structure 406.
In other embodiments, as shown in FIG. 6, the set screw 440 may
comprise what is termed a "swivel tip" set screw, having a tip 456
with a bearing surface 458. The tip 456 may be capable of swiveling
relative to the remainder of the set screw 440 in a manner to
self-orient the bearing surface 458 with the receiving surface 446
of the receiving formation 442 when the set screw 440 is threaded
into place against the planar receiving surface 446. As shown, the
bearing surface 458 of the tip 456 of the set screw 440 and the
receiving surface 446 of the receiving formation 442 of the
formation-engaging structure 406 may each be planar; however, in
other embodiments, other configurations are possible. In further
embodiments, as shown in FIG. 7, the receiving formation 442 of the
formation-engaging structure 406 may include a planar receiving
surface 446a oriented at an inclined angle A relative to a
longitudinal axis L of the formation-engaging structure 406. In
such embodiments, the bearing surface 458 of the tip 456 of the
swivel-tip set screw 440 may also be planar and the tip 456 may
swivel to self-orient the planar bearing surface 458 to be
co-planar with the inclined receiving surface 446a of the receiving
formation 442 when the set screw 440 is threaded into place against
the inclined receiving surface 446a.
In additional embodiments, at shown in FIG. 8, the receiving
surface 446a of the receiving formation 442 of the
formation-engaging structure 406 may be planar and inclined at an
angle A relative to the longitudinal axis L of the
formation-engaging structure 406 and the tapped bore 444 may extend
through the blade 416 at an angle relative to the longitudinal axis
L of the formation-engaging structure 406 and substantially
perpendicular to the inclined, recessed receiving surface 446a. In
such embodiments, the receiving formation 442 in the sidewall 423
of the formation-engaging structure 406 may be substantially
aligned with and oriented at the same angle as the tapped bore 444.
It is to be appreciated that the orientation of the inclined,
planar receiving surface 446a of the receiving formation 442 shown
in FIGS. 7 and 8 may increase the retaining force into the blade on
the formation-engaging structure 406.
For reference, FIG. 9 illustrates a perspective view of the
receiving formation 442 of the formation-engaging structure 406
shown in FIGS. 4 and 5; FIG. 10 illustrates a perspective view of
the receiving formation 442 of the formation-engaging structure 406
shown in FIG. 6; and FIG. 11 illustrates a perspective view of the
receiving formation 442 of the formation-engaging structure 406
shown in FIG. 7. FIG. 11 illustrates a perspective view of the
receiving formation. It is to be appreciated that the
configurations and orientations of the receiving formations 442 of
the formation-engaging structures 406 of the present disclosure are
not limited to those described in relation to FIGS. 4 through
11.
It is to be appreciated that, while the foregoing embodiments
disclose retaining features for retaining the formation-engaging
structures to blades of an earth-boring tool, the retaining
features may also be incorporated to retain formation-engaging
structures on an earth-boring tool lacking blades.
Although the foregoing description contains many specifics, these
are not to be construed as limiting the scope of the present
invention, but merely as providing certain exemplary embodiments.
Similarly, other embodiments of the invention may be devised that
do not depart from the spirit or scope of the present disclosure.
For example, features described herein with reference to one
embodiment also may be provided in others of the embodiments
described herein. The scope of the invention is, therefore,
indicated and limited only by the appended claims and their legal
equivalents, rather than by the foregoing description. All
additions, deletions, and modifications to the disclosed
embodiments, which fall within the meaning and scope of the claims,
are encompassed by the present disclosure.
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